Classifications

• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
  • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
  • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
  • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
  • H01F41/06—Coil winding
  • H01F41/079—Measuring electrical characteristics while winding
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
  • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
  • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
  • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
  • H01F41/06—Coil winding
  • H01F41/064—Winding non-flat conductive wires, e.g. rods, cables or cords
  • H01F41/066—Winding non-flat conductive wires, e.g. rods, cables or cords with insulation

Definitions

• the present invention relates to the production of electrical equipment which uses windings made of enamelled copper wire with a circular cross-section, and more particularly it relates to a system for producing the windings, improved to allow the achievement of the highest product quality.
• Any changes to the design data are then made : based on the production results, based on specific requests, or based on indications supplied by the quality control.
• the process for actually making the product is affected by a large number of variables which may cause even significant deviations in the characteristics of the wire used to form the winding. This is easier to understand by referring, for example, to the production of a high voltage stray flux transformer, more commonly known as a neon transformer, specific for switching on discharge lamps, for lighting.
• a high voltage stray flux transformer more commonly known as a neon transformer, specific for switching on discharge lamps, for lighting.
• Such a transformer has an active part relating to the winding which consists of one primary and two opposite secondary windings.
• the output voltages may reach 15,000 Volts with maximum secondary short circuit currents of 300 mA.
• Such a type of product may have secondary windings with quadrangular shapes which mean that during winding the wire is subject to bending conditions which may locally and significantly influence its initial characteristics. Moreover, such deviations may be further enhanced when transformers with small dimensions are to be obtained or in any case in line with the strictest product and installation regulations. Therefore, in this case there are many variables to consider, and they have many mutual influences.
• the most suitable copper cross-section it is important to take into account the most suitable copper cross-section; the most suitable covering films for insulation and covering hardness; the copper material with the most suitable stretching must be selected; sufficient electric rigidity both at ambient temperature and at high temperatures; the covering with a maximum number of leaks on the insulating film complying with the relevant regulation; and/or a material with a number of other defects created during laying of the film and in compliance with the relevant regulation.
• the main aim of the invention is to overcome the afore-mentioned disadvantages by providing a production process able to simulate use of the enamelled wire, that is to say, to simulate the windings in such a way as to allow studying in advance of the consequent phenomena and their influences on significant product parameters; and/or able to measure simulated and/or actual losses of characteristics; and/or able to control on-line, during the production process, several characteristics of the enamelled wire in such a way that they can be suitably managed to obtain predetermined performance on the electrical equipment for which the winding is intended.
• FIG. 1 is a functional block diagram showing a first embodiment of the system in accordance with the invention
• Figure 2 is a functional block diagram showing a second embodiment of the system
• Figure 3 is a block diagram of a section of the system which can advantageously be integrated in the diagrams of Figures 1 and 2.
• Figures 1 is a block diagram of a piece of equipment which corresponds to a first embodiment of the system in accordance with the invention, labelled 100 as a whole.
• the piece of equipment 100 comprises a block 105 identifying a wire stretching apparatus, in particular of the electronic type, with a relative control that can be set according to requirements for the preliminary study of the characteristics of the wire, for controlling the wire characteristics, or for simulating particular wire stretching intensities.
• the block 104 identifies an apparatus for guiding and stabilising the wire before it is fed into a subsequent block labelled 103.
• the block 103 symbolically represents an apparatus for reading the external diameter of the wire, an apparatus which in particular may comprise an optical micrometer, designed to detect the diameter of the wire on two crossed axes, also identifying wire section outline ovalisation.
• the reading apparatus preferably electronically-controlled, can also acquire data on-line.
• the piece of equipment 100 also comprises a first block 101 symbolically representing as a whole a wire winding unit, with a set of motor-driven spindles, equipped with layering means and managed by electronic control means operated, for example, by a programmable logic controller, hereinafter referred to briefly as a PLC.
• a PLC programmable logic controller
• the rotary spindles may have various shapes and sizes. For example, they may be cylindrical or quadrangular, depending on requirements and the features of the electrical equipment for which they are intended.
• the functional operating parameters of the rotary spindles can be set using the PLC in various ways, depending on whether or not winding is performed to be studied, for example in a preliminary way to find the optimum operating conditions for subsequent production, or for controlling the actual operating conditions of current production, or to simulate winding and/or steps in its progress.
• the block 107 indicates a hardware unit for controlling the entire piece of equipment, housed in a supporting structure.
• the block 113 indicates as a whole software means supplied with the system 100 disclosed.
• the software means operate in ways symbolically represented with a block 108 identifying a software for simulating winding phenomena, acceleration and deceleration ramps of winding spindle motion - stop transients, as well as ramps for wire layering in the winding as a whole.
• the block 109 symbolically identifies a PLC control software unit which controls and checks the winding spindles.
• the block 110 identifies a software unit for detecting data and organising it, from the PLC, from the optical micrometer of block 103, from the electronic wire stretcher of block 105.
• the block 113 also comprises a block 111 identifying a software for management of an archive of data about internal control specifications (SPI) and which can activate a process control (APC) which substantially compares the data relative to the expected technical characteristics and that relative to the actual technical characteristics of the wire (operator data, machine data, times, materials) and which prevents use of the wire if it does not conform to the specifications.
• SPI internal control specifications
• API process control
• the block 112 identifies a software product which designs, simulates, organises and manages all of the various areas of the system.
• the piece of equipment 100 being used allows, through the software means relative to block 108, mechanical and dynamic modelling for simulating actual winding, setting the operating data for example according to the type of wire, the type of support for its winding, the distances between the operating elements used for winding (shuttle, wire guide and wire stretcher), operating angles between the elements, operating element accelerations and decelerations, spindle speed of rotation: these parameters all, over time and in varying degrees and different ways, being able to influence the initial characteristics of the wire (detected and saved in the relative archives), modifying them to a greater or lesser extent during the winding process.
• use of the software relative to block 108 allows the following to be identified: torque, radial force, tangential force, axial force and tension applied to the wire at the various moments of the winding process.
• Figure 2 shows a second embodiment of the system - labelled 200 as a whole - comprising a block 204 and a block 203 identifying as a whole an apparatus for guiding and stabilising the wire before it reaches an apparatus 300 for reading the diameter, not illustrated in the accompanying drawings, which operates similarly to that shown in Figure 1 with the block 103, but unlike the latter consists for example of an optical microscope, supported by suitable software, for measuring diameters, identifying ovalisation and using enlargement to detect surface faults on the wire.
• Blocks 204 and 203 also symbolically represent operations which are similar to those already described relative to Figure 1, therefore, a detailed description is not provided here.
• Blocks 212 and 213 symbolically represent gauges which allow the wire to run on special "V"-shaped guides, fully known and defined by specific dimensional testing standards: standards which make a distinction between two different wire size ranges which can refer symbolically to one or the other of the blocks.
• Block 211 symbolically represents a measuring instrument for measuring insulation continuity at a high voltage. For the two size ranges with different wire thickness, relative to blocks 212 and 213, this instrument is used to detect the insulation continuity with a specific electric test circuit.
• the blocks 210 and 209 symbolically represent, respectively, pieces of equipment 210 allowing the wire to run on pieces of felt soaked with saline solution and a test instrument with which, by means of a specific electric test circuit, it is possible to measure the insulation continuity for the length of the wire detected.
• the system 200 also comprises blocks 201, 202 and 219 which, similarly to what was said relative to Figure 1 , respectively symbolically represent: wire winding on a set of motor-driven spindles having various shapes, controlled by a PLC (Blocks 201 and 202). Again, the operating parameters with which winding is performed are controlled by control software (Block 219) which, similarly to what has already been said relative to Figure 1, can be set according to various requirements: for studying, controlling and simulating winding.
• the system 200 of Figure 2 also comprises a block 208 symbolically representing equipment for PLC management and control of temperatures, on a test gauge, for high voltage puncturing of the wire covering.
• Two other blocks 206 and 207 identify two types of test: the first at ambient temperature, the second at a high temperature.
• the block 205 symbolically represents a test instrument which, with reference to the two conditions relative to blocks 206 and 207, detects the puncture voltage and relative current, using a specific electric test circuit.
• the blocks 214 and 215 respectively identify an instrument for detecting the direct current electrical resistance at 2O 0 C of a predetermined length of copper wire; and a specific piece of equipment for that test.
• the block 230 identifies software means which manage the system 200.
• the means 230 include blocks 217 and 218 respectively identifying: the hardware for controlling the entire piece of equipment and a software module that operates similarly to the block 118 of Figure 1 , simulating winding and setting the operating data, hi the present embodiment of the system 200 the software means 230 also include a block 220 symbolically identifying a software for detecting data relating to: PLC, electronic wire stretcher, resistance, puncturing at ambient and high temperature, and insulation continuity at low and high voltage.
• hi block 230 there are also blocks 221 and 222, similar to blocks 111 and 112 of Figure 1, therefore, a detailed description is not provided here.
• 200 may advantageously also include a piece of equipment for managing the wire mechanical characteristics.
• Said piece of equipment is illustrated in Figure 3 and labelled 300 as a whole. It comprises blocks 301, 302, 320 interfacing with the software means, which for the different embodiments are represented with the block 113 or 230.
• the block 301 symbolically represents an apparatus for ultimate elongation and ultimate tensile strength tests on the wire.
• the block 302 symbolically represents an apparatus used for spring-back tests, that is to say, to identify the unwinding measured in degrees that the wire wound in the shape of a spiral coil can adopt once it is left free.
• the block 320 symbolically represents with the block 303 the spindles for spring-back tests; with the block 304 spindles for testing wire flexibility and adherence and with block 305 spindles for wire heat shock tests.
• a block 306 symbolically represents a crucible apparatus for testing loss of mass relating to the wire covering and indicating its degree of polymerisation.
• the system disclosed fully achieves the aim of being able to measure, analyse and control all electrical, mechanical and technological characteristics of the wire both on acceptance and during the production process so as to manage the production operating parameters flexibly and in real time in such a way as to give the electrical product for which they are intended windings of the highest production quality and the best level of reliability in use.

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Citations (9)

• 2007
  • 2007-10-02 SM SM200700039A patent/SM200700039A/it unknown
• 2008
  • 2008-09-19 WO PCT/SM2008/000007 patent/WO2009045180A1/en active Application Filing

Patent Citations (9)

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